Homebuilt 2004 Ford Bronco Is One Cool Rig

This homebuilt Ford Bronco is an extensive build based on a 2004 F-150.

By Brett Foote - September 11, 2023
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DIY Bronco
1 / 7
Birth of an Idea
2 / 7
Chop Job
3 / 7
Non Removable Top
4 / 7
Otherwise Stock
5 / 7
Lessons Learned
6 / 7
Getting Back To It
7 / 7

DIY Bronco

After a strong, multi-decade-long run, the Ford Bronco was discontinued following the 1996 model year and didn't return until 2021, largely because fans of the SUV had been clamoring for it ever since it left this earth. Thus, we saw our fair share of homebuilt Broncos over the years, some of them rather tasteful and others, well, not so much. However, this one that's up for grabs on Facebook Marketplace - built using a 2004 F-150 as its base - is pretty impressive for a number of reasons.

Photos: Facebook Marketplace

Birth of an Idea

The owner of this rig - Dan Hickey - told The Drive that he decided to transform the F-150 into a Bronco because, at the time, he had purchased a new truck, yet this one was still in nice shape. Unlike today, 2004 F-150s weren't exactly worth a ton of money until the recent used vehicle surge, so it just made sense to keep it and transform it into something cool.

Photos: Facebook Marketplace

Chop Job

As one might imagine, converting an F-150 into an SUV isn't exactly an easy task. Hickey obviously had to strip the truck down to its bare bones before he broke out the heavy equipment and cut the frame, proceeding to remove 2.5 feet from its length. Hickey also added guides inside the frame that essentially act as backer plates to give it some added strength.

Photos: Facebook Marketplace

Non Removable Top

Next, it was time to cut up the cab, as well as figure out how to enclose the rear section of the truck to transform it into a proper SUV. Hickey accomplished that by using a Lear cap, which isn't removable, as that would have been a pretty difficult job, according to the vehicle's owner. Regardless, it gets the job done and makes room for a couple of passengers where the bed used to be.

Photos: Facebook Marketplace

Otherwise Stock

Hickey had to fabricate a custom body lift for his F-150 so that it would clear the revamped frame, and he added a roll hoop to boost rigidity. Other than these modifications and a set of Raptor wheels wrapped with BFGoodrich all-terrain tires, it's basically stock - right down to the original 5.4-liter V8 with around 115k miles on the clock.

Photos: Facebook Marketplace

Lessons Learned

There is some room for improvement, of course, outside of figuring out how to make the top removable like a proper Bronco. Hickey notes that specifically, the carpeting around the wheel wells doesn't look the best, but he hopes to one day take what he learned from this project and apply it toward a future build.

Photos: Facebook Marketplace

Getting Back To It

"We started the project before the used truck market really shot up. It took almost 2 years to complete," Hickey said. "Now with used trucks being so expensive, I put the second one on hold. We have come up with so many easier ways to complete the next one along with alterations we would do for slightly different proportions. I hope to get back to it someday."

Photos: Facebook Marketplace

>>Join the conversation about this home-built 2004 Bronco right here in the forum.

For help with your maintenance and repair projects, please visit our how-to section of Ford-trucks.com.

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